Engine Components and

Cycle
Engine Basic Components

Camshaft

Spring
Spark
Guide
plug
Stem
Air manifold

Valve seat

Piston
 Engine Basic Components
Air cleaner

Carburetor Camshaft

Rocker arm

Intake valve

Cam sprocket Exhaust valve

Piston

Connecting
Timing belt rod

Timing belt Crankshaft

tensor

Crank sprocket Oil pump

Oil pickup
 Cylinder Block

•Cylinder block provide rigidity and strength

•Contains various passages and galleries, which
coolant and oil circulate
•During manufacture
➔Bored
-Cylinder
-crank-shaft main bearing support

➔machined
-Cylinder head
-water pump
-oil filter housing
-oil pan
-timing covers
-flywheel housing
 Cylinder Block

Air-Cooled Cylinder Block

•Cylinder barrels separate from each other
•Bolted to crankcase
•Constructed by cooling fins
•But, only fins are not enough
•Large volumes of air forced by fan to go
around the fins
 Cylinder Bores and Liners

•Engine block are expensive:

➔must have a long service life
➔use replaced cylinder liner
•Types
➔cast cylinder block
➔flanged dry liners
➔wet liners
Cylinder block Replaceable Replaceable wet liner
machined in the flanged dry liner in direct contact with
block coolant
Cast Cylinder Block
•Used in smaller and less expensive engine
•Bores are machined
•If cylinders are damaged:
➔cylinder bores can be bored out
➔use corresponding oversize piston and ring combination
➔if enlarged beyond limit➔ fitting straight liner
 Cylinder Bores and Liners

Flanged Dry Liners •If too loose

•Cylinder liner are manufactured as a separate item ➔poor heat conduction
•Thin metal sleeves (2mm) fitted into the cylinder ➔rise in cylinder temperature
bores
➔rings and piston to scuff the cylinder
•Do not contact with engine coolant wall
•The fit is important➔ amount of heat conducted •If too tight
•Can be pressed into the cylinder bore by hand➔ ➔a fit may break on assembly
clearance (0.025~0.04)
➔distort the surface of the cylinder wall
 Cylinder Bores and Liners

•Wet/dry liners are

designed to have
protrusion above
the surface of the
cylinder block
(0.1~0.17mm)
•To ensure the
liner is held firmly
Wet Liners on its seat when
the cylinder head
•Surrounded by coolant is secured to the
cylinder block
•Required to be sealed at the top flange and at its
lower skirt •Clevis seal are used to:
•At the top➔ metal to metal seal or copper gasket ➔protect the o-rings
between the liner flange and the counterbore seat ➔prevent corrosion occurring adjacent to the o-ring
•At the lower end sealed by sealing area
➔o-rings •Thickness of the wet liner is much greater➔ not
have support of the block
➔clevis seal
•Weep holes➔ identifying cylinder liner seal leakage
Cylinder Head
1. Cylinder head 16. Wear plate
2. Washer 17. Valve guide
3. Capscrew- 18. Pipe plugs
short
19. Ring dowel
4. Capscew-
long 20. Pipe plug
5. O-ring 21. Valve seat
inserts
6. Injector
sleeve 22. Valves
7. Crosshead 23. Head gasket
guide
8. Split Ting
dowel
9. Cross head
10. Adjusting
screw
11. Locknut
12. Half collets
13. Spring
retainer
14. Valve springs
15. Valve seal
 Cylinder Head

•Constructed of cast iron and is bolted to the •Made of special alloy steel
cylinder block •Some intake valves having a larger
•Forms the upper part of the combustion chamber head
•Provide inlet and outlet ports •Can be ground at either of two angles
(300 ~450)
•Provide passages for circulation of coolant
•Ground at 450 angle (exhaust)
•Locate injector and valves mechanism
➔25% more seating force
➔more efficient cleaning and
•A gasket is installed between the cylinder head sealing action
and the cylinder block
•Ground at 300 angle (intake)
➔seal the combustion chamber and all water
and oil passages ➔create less restriction to air flow
•Variety of size: •When head sizes are the same,
manufacturers stamp it by “EX” and “I”
➔1 cylinder head to cover 6 cylinders
•Standard diesel engine uses 2 valves per
➔2 cylinder heads to cover 4 cylinders cylinder
➔1 cylinder head to cover 1 cylinder •High performance diesel engines uses 4
valves per cylinder
•Detroit 2-stroke engine➔ 4 exhaust valves
 Crank Shaft

• The crankshaft, sometimes casually abbreviated to crank, is the part of an engine which translates
reciprocating linear piston motion into rotation.
• It typically connects to a flywheel, to reduce the pulsation characteristic of the four-stroke cycle.
• The distance of the axis of the crank throws from the axis of the crankshaft determines the piston stroke
measurement, and thus engine displacement. A common way to increase the low-speed torque of an
engine is to increase the stroke. This also increases the reciprocating vibration, however, limiting the high
speed capability of the engine. In compensation, it improves the low speed operation of the engine, as the
longer intake stroke through smaller valve(s) results in greater turbulence and mixing of the intake charge.
For this reason, even such high speed production engines as current Honda engines are classified as
"under square" or long-stroke, in that the stroke is longer than the diameter of the cylinder bore.

• In engines other than the flat configuration, it is necessary to provide counterweights for the
reciprocating mass of each piston and connecting rod to improve engine balance. These are typically cast
as part of the crankshaft but, occasionally, are bolt-on pieces. This adds considerably to the weight of the
crankshaft. Crankshafts from Volkswagen, Porsche, and Corvair flat engines, lacking counterweights, are
easily carried around by hand, compared to crankshafts for inline or V engines, which need to be handled
and transported as heavy chunks of metal.
Crank Shaft
 Cam Shaft

• The camshaft is an apparatus often used in piston engines to operate poppet valves. It consists of a
cylindrical rod running the length of the cylinder bank with a number of oblong lobes or cams protruding
from it, one for each valve. The cams force the valves open by pressing on the valve, or on some intermediate
mechanism, as they rotate.
• Since the valves control the flow of air/fuel mixture intake and exhaust gases, they must be opened and
closed at the appropriate time during the stroke of the piston. For this reason, the camshaft is connected to
the crankshaft either directly, via a gear mechanism, or indirectly via a belt or chain called a timing belt or
timing chain.
• Depending on the location of the camshaft, the cams operate the valves either directly or through a linkage
of pushrods and rockers. Direct operation involves a simpler mechanism and leads to fewer failures, but
requires the camshaft to be positioned at the top of the cylinders. In the past when engines were not as
reliable as today this was seen as too much bother, but in modern gasoline engines the overhead cam system,
where the camshaft is on top of the cylinder head, is quite common. Some engines use two camshafts each
for the intake and exhaust valves; such an arrangement is known as a double or dual overhead cam (DOHC),
thus, a V engine may have four camshafts.
Cam Shaft
 Piston
Function:
1. To create a seal within the cylinder
2. To transmit the forces of combustion via
the connecting rod to the crankshaft
3. to acts as a pump on the intake and
exhaust strokes

Characteristics:
1. Light weight (cast from aluminium alloy)
2. Good strength
3. High heat conductivity

Types of piston:
1.Trunk type piston
2.Two-piece design
 Piston Type
Two-piece Piston
• Allows for easy access
to the crown and top
of the skirt area to
construct more
efficient oil galleries.
• Steel crown being a
stronger material
• Top ring position is
higher
➔reducing the diad air
volume
Trunk type piston: ➔reduce HC
1.Piston crown (combustion chamber)
4. Skirt more isolated from the high temperature piston
2.Compression ring grooves crown
3.Oil ring groove 5. Skirt-to-cylinder wall clearance can be smaller
4.Skirt ➔minimizing piston slap and engine noise
6. Piston more stable in bore
➔prevent the piston crown and rings form tilting in
the bore
 Cam-ground Shape

• Greater amount of metal in the

piston pin boss area
• Uneven expansion of metal
• Constructed oval in shape to
ensure piston will expand into
round shape from heat of
combustion
• Engine must run at correct
operating temperature
➔if not, resulting in piston slap and
accelerated engine wear
 Piston Pin

• Made from hardened alloy steel

• Pin is hollow to reduce its weight and subsequent inertia force
• Different methods of mounting:
• Located off the centre line of the piston towards the power thrust side of the piston
• Less tilting of the piston during the power stroke
• Piston slap and engine noise are kept minimum
 Piston Ring

Compression ring
•Function:
➔seal against the cylinder wall
➔transfer heat
•Compression and combustion gases
help in forcing the ring to seal against
the cylinder wall
•Many are chrome
 Oil Ring

Oil control rings:

•Functions:
➔to control the amount of oil on the
cylinder walls
➔to provide adequate lubrication to
the compression rings
•Too much oil left allowing the oil to enter and
burnt in combustion chamber
•Too little oil causing scuffing and scoring
 Four Stroke SI Cycle
Four Stroke Spark Ignition (SI) Engine

Stroke 1: Fuel-air mixture introduced into cylinder through intake

valve
Stroke 2: Fuel-air mixture compressed
Stroke 3: Combustion (roughly constant volume) occurs and
product gases expand doing work
Stroke 4: Product gases pushed out of the cylinder through the
exhaust valve
FUEL
A
I Ignition
R

Fuel/Air
Mixture Combustion
Products

Intake Compression Power Exhaust

Stroke Stroke Stroke Stroke
 P-V Graph 4-Stroke SI Cycle
One power stroke for every two crank shaft revolutions

Pressure Spark

Exhaust valve
Exhaust opens
valve
closes

1 atm Intake valve

closes

TDC BDC

Cylinder volume
 Two-Stroke SI Cycle

Two Stroke Spark Ignition Engine

Stroke 1: Fuel-air mixture is introduced into the

cylinder and is then compressed, combustion
initiated at the end of the stroke

Stroke 2: Combustion products expand doing

work and then exhausted

* Power delivered to the crankshaft on every

revolution
 Two-Stroke SI Cycle Cont.

Exhaust
port

Fuel-air-oil
mixture
compressed
Check
valve
Expansion Exhaust Intake (“Scavenging”)
Crank
shaft

Fuel-air-oil
mixture

Compression Ignition
 Scavenging in Two-Stoke

Cross Loop Uniflow

Scavenging is the process of replacing the exhaust

gas in a cylinder of an internal combustion engine
with the fresh air/fuel mixture (or fresh air, in the
case of direct-injection engines) for the next cycle
 Two-Stroke Adv. and Disadv.

Advantages of the two stroke engine:

• Power to weight ratio is higher than the four stroke engine

since there is one power stroke per crank shaft revolution.
• Simple valve design

Most often used for small engine applications such as lawn

mowers, marine outboard engines, motorcycles….

Disadvantages of the two-stroke engine:

• Incomplete scavenging or to much scavenging

• Burns oil mixed in with the fuel
 Scavenging in Two-Stoke

ASSIGNMENT 3
1. Which is more efficient, the four-stroke or the two-stroke engine? Why? What is the
range of the engine efficiency for two stroke engine?
2. Why you don’t see two-stroke engines in car? What are problem with two-stroke
engine?
3. Discuss three types of two-stroke engine available in the market

Due date is on Monday 10th November 2024.